Electrical connector cluster assembly with motor protection

ABSTRACT

The invention comprises an apparatus especially adapted for connecting hermetic compressor motor leads disposed in a cluster to a hermetic shell-mounted terminal of the type having three closely spaced pins with flat tabs thereon. The cluster assembly includes a block with cavities therein in an orientation in which the contact sockets are relatively flat and disposed at equilateral angles to each other so as to align with the tabs on the pins and so that the contact wires extend in a pinwheel arrangement at the edge of the block. An additional socket is provided in the block for reception of a thermal sensitive device that provides overload protection for the compressor motor, with the thermal sensitive device wired in series with one of the wires of the pinwheel arrangement.

United States Patent [72] inventor Donald W. Foster 3,345,605 10/1967 Looke t. 339/192 RL Columbus, Ohio FOREIGN PATENTS P 3 970 618,94l 3/1949 Great Britain 337/191; E g'f g; 1971 672,699 5/1952 Great Britain 339/147 P l 73] Assignee Westinghouse Electric Corporation Prinmry llme A. Leppink Pittsburgh, p Assistant ExaminerLawrence J. Staab Attorneys-F. H. Henson, E. C. Arenz and R. B. Farley [54] ELECTRICAL CONNECTOR CLUSTER ASSEMBLY WITH MOTOR PROTECTION ABSTRACT: The invention comprises an apparatus especially 7 C| i ,6 D i Fi adapted for connecting hermetic coznpressor motor leads disposed in a c uster to a hermetic she l-mounted terminal of [52] US. Cl the type having three closely spaced pins with flat [abs 3 ll H thereon. The cluster assembly includes a block with cavities [51] lnt.Cl H01r33/070, therein in an orientation in which the Contact Sockets are fell f h H0 2 tively flat and disposed at equilateral angles to each other so as [50] Fieldo Searc .3 7/ 2, to align with the tabs on the pins and so that the Contact wires 191 19] 191 1 1 extend in a pinwheel arrangement at the edge ofthe block. An 1 I additional socket is provided in the block for reception of a [56] References Cited thermal sensitive device that provides overload protection for the compressor motor. with the thermal sensitive device wired UNITED SZATES PATENTS 33 B X in series with one ofthe wires of the pinwheel arrangement. l,857,899 5/1932 Wal er 9 0 U l8 1 l6 x 13 l 5 IO p l |2- I 3Q- I6 PATENTEDunv 23 ml 3, 22,94

sum 1 BF 2 FIG.4.

INVENTOR Donald W. Foster I BY 441M) (212L114? ATTORNEY BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to an electrical connector cluster assembly with an overload means and, more specifically, relates to an electrical connector cluster assembly and an overload protection means that are adapted for connecting a hermetic compressor motor to the hermetic shell-mounted terminal of the type having three closely spaced pins with flat tabs thereon.

2. Description of the Prior Art Although the use of an electrical connector cluster assembly of the general type herein disclosed is known and has been described, for example, U.S. Pat. No. 3,345,605, such connector cluster assemblies have not included any means for protecting the hermetic motor from overloading and thereby overheating so that such means had to be provided somewhere else within the hennetic shell and this required a consequent additional assembly operation and the added cost required by this assembly operation. The present invention obviates such a requirement.

The nature of the instant invention may be more readily appreciated if the environment in which the collector cluster assembly with overload protection is detailed. Small hermetic compressors of the type utilized in refrigerators, freezers and air conditioners are mass produced for incorporation in mi]- lions of such appliances each year. Most manufacturers of small hermetic compressors utilize a standard hermetic terminal which carries three pin conductors sealed in an insulating relationship through the shell of the hermetic compressor. Although collector cluster assemblies have been utilized to provide a convenient connection for the leads of the compressor motor to the pins provided in the side of the hermetic shell (c.g., U.S. Pat. No. 3,345,605), none of these cluster assemblies have heretofore utilized an overload protection as a portion of their assembly. Thus, this overload protection had to be provided alternately in the wiring leading to the hermetic shell or provided within the hermetic enclosure, itself. In both of these cases, the assembly of the hermetic compressor and its electrical connecting wires was somewhat complicated and thereby required more time and additional costs. If an overload protection was provided within the electrical connector cluster assembly, then a large amount of assembly time could be eliminated and the overload protector means prewired into the collector cluster assembly to provide the overload requirements of the compressor motor.

SUMMARY OF THE INVENTION In accordance with the principles of this invention, a mounting block is provided with a number of connector cavities for holding a series of connectors in a proper array to fit the pins extending from a hermetic enclosure. Connectors including their ferrules are formed to accommodate the cavities provided in the mounting block, with these cavities being arranged so that each conductor emerges from the edge of the mounting block at a location closely adjacent to the connector cavity. Disposed outwardly of the connector cavities and substantially aligned with a base of the block, is an additional cavity which is shaped so as to rigidly hold therein an overload protector element. This cavity includes a trough portion for the overload protector and a part of the terminals which extend from the overload protector, with a lead attached to one of these terminals extending to the other two wires extending from the connector block and the other two wires extending from the opposite terminal of the overload protector around the mounting block to one of the three connectors disposed in one of the connector cavities. The cavity provided for the overload protector includes means for aligning the terminals which extend therefrom and also means formed by a substantially semiannular groove for holding the overload protector in the proper location within the cavity.

DRAWING DESCRIPTION FIG. 1 is a plan view of the rear or cover side of a cluster assembly and overload protector according to the instant invention;

FIG. 2 is a plan view of the rear side of the mounting block with the cover removed and the connectors omitted;

FIG. 3 is a sectional side view corresponding to one taken along line III-III of FIG. 2;

FIG. 4 is a plan view of the cover for the mounting block;

FIG. 5 is a fragmentary perspective view of one corner of the mounting block with a connector for the corner cavity shown in exploded relation to the block; and

FIG. 6 is a view similar to FIG. 5, but showing the overload protector in exploded relation to its cavity.

DETAILED DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail in connection with the accompanying drawings which illustrate one embodiment thereof by way of example and wherein a connector cluster assembly 8 is shown in FIG. 1 in its assembled form with three electrical conductors 10, I2, and 14 emerging from three underlying cavities l6, l6 and 16. These cavities are situated at peripherally spaced locations about the edge of a generally truncated, peak-shaped insulating block 18, and are at equilateral angles to one another in the truncated triangular portion on the insulating block. The lead wires 10 and 12 are wrapped around the peripheral edge of the insulating block 18 from their point of emergence to form a three wire group with another wire conductor 20 that extends outwardly from a cavity 24 in the rectangular part of the insulating block 18. These three electrical conductors are fastened together outwardly of the truncated, peak-shaped insulating block 18 by and suitable means such as a cord 26 wrapped around them, this cord being disposed at the point where they may be forced into a closely adjacent position to form a grouping that extends to and is connected to an electrical supply (not shown).

A cover 28 that protects the rear face of insulating block 18 is generally hexagonally shaped with an extending tail that projects from one side of the hexagon shape. This cover is placed over the rear of the insulating block 18 and abuttingly fits with three of its side edges 30, 30 and 30 against tabs 32, 34, and 36 provided integral with the peak-shaped insulating block 18. These tabs take the form of raised abutments at three corners of the block 18 and therefrom conveniently locate the cover 28 relative to the block 18 when these two elements are in assembled relationship. The cover 28 is conventionally fastened to the block 18 by a rivet or screw 36 that my extend through a bore 38 in the peak-shaped insulating block 18 (FIG. 3) with a nut or a peened over rivet head (not shown) being disposed in a blind bore 40 that communicates and is coaxially aligned with the bore 38.

Referring now to FIGS. 2, 3 and 5, the three cavities generally denoted 16 are provided adjacent each corner of the block l8 to receive a connector 42 secured to the end of a motor lead wire. Each connector includes conventionally shaped clip portions 44, 44 adapted for a slip-on connection to a hermetic terminal pin, a ferrule portion 46 which is crimped onto its respective bare lead wire and generally encompasses the lead wire conductor so as to be attached to it, both physically and electrically, and an intermediate web portion 48 disposed so as to extend between ferrule portion 46 and the clip portions 44, 44. It should be noted that the web portion 48 is disposed at an acute angle to the plane of the ends of the clip portion 44, 44 so that each connector 42 can seat on a substantially similar shaped portion of the underlying cavity 16.

Each cavity 16 which receives a connector 42 includes a clip receiving opening 50 that extends between a rear face 52 and a front face 53 of the truncated peak-shaped mounting block 18. Each clip receiving openings merges with a receiving trough-shaped recess 54 in the block 18 disposed outwardly of it, relative to the sides of the mounting block. Each trough-shaped recess is open at one end to the edge of the block and open adjacent its other end to a wall 56 having its edge 58 recessed from the rear face of the block 18. The

trough-shaped recess 54 that receives the ferrule portion 46 and the edge 58 are generally cut across a corner of the triangular portion of the peak-shaped block 18 with only one end of the trough-shaped recess 54 to open the edge of the block.

Each of the connectors 42 seats in a cavity 16 with its clip portions 44, 44 fitting in the clip receiving opening 50 and extends between the rear face 52 and the front face 53 of the block 18. The ferrule portion 46 lies in the trough 54 and recessed edge 58 of the block receives the web portion 48 of the connector 42. The opening, trough and recessed edge are designed to allow freedom of movement of the connector in the cavity so that the connector is essentially self-aligning with the pins on whichit is pushed to make an electrical connection.

The orientation of each of the cavities 16 is such that the lead wires emerge from the edges of the blocks in what may be aptly termed pinwheel fashion. As such, the lead wires emerge at an obtuse angle relative to the adjacent edges of the mounting block so that the flexible leads may be easily wrapped around the edges of the mounting block without departing from it.

The lead wire 12 extends from what may be considered the uppermost cavity 16 in this manner, and is then attached to an overload device 60 such as a conventional thermal sensitive device disposed within the cavity 24. A terminal 62, rigidly at tached to the overload device 60, may provide an easy connection between this electrical conductor and the overload device 60. The cavity 24 is formed with a substantially semicircular shape 64 (FIGS. 3 and 6) for nearly its full linear extend. Adjacent the ends of the cavity 24, the semicircular recess 64 is terminated by means of walls 66, 66. Each of the walls 66, 66 includes extending through it, a U-shaped channel 68 which opens outwardly to the edge of the mounting block to thereby provide a guiding and alignment means for the electrical terminal which extends outwardly therethrough from the overload device 60. Of course, the opposite end of the overload device 60 includes a terminal 70 similar to the aforementioned terminal 62. This terminal (terminal 70) has attached to it the electrical connector 20, with this electrical connector taking a very sharp turn around what may be considered the bottom edge of the insulating block 18 to form one of the wires of the three wire assemblage which are tied together by the cord 26.

In order to properly transversely space the overload device 60 within the cavity 24, a semicircular groove means 72 is provided immediately between the walls 66, 66. The overload device includes, adjacent one of its ends, an integral circular flange 74 which fittingly is inserted into the semicircular groove 72 to thereby positively position the overload device 60 within the cavity 24.

With the completion of the binding of the connecting wires l0, l4 and 20, the truncated, peak-shaped insulating block 18 and the three electrical connectors extending therefrom form essentially a single assemblage which may be easily handled and engaged, for example, with a three-prong plug which may be disposed on the wall of the hermetic shell for the compressor (not shown). Such a plug is shown in FIG. of U.S. Pat. No. 3,345,605 and reference may be had thereto for a more complete understanding of the manner of the connection of the electrical connector cluster assembly with overload protection of the instant invention to such a plug member.

It will be appreciated from the foregoing description that a cluster assembly with overload protection has been provided which may be easily utilized as a single assembly and plugged to a three-prong plug provided for it. Because of its construction, overload protection for a compressor is provided which is in a series relationship with one of the electrical connectors that forms the three-connector assembly. At the same time, the thickness of the cluster assembly is held to a minimal value since the electrical connectors, their terminals and the overload protection means are disposed in cavities formed in the mounting block.

Although a single embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that many modifications can be made therein without exercising the inventive faculty. What is claimed is: 1. a cluster assembly for making a gang connection to a plural post terminal including;

a. a mounting block having a peripheral edge and a pair of oppositely disposed faces, and mounting block having a plurality of cavities disposed in one of said faces, and I cavities opening to said peripheral edge,

b. electrical connector means disposed in at least some of said cavities,

c. an overload protector means disposed in one of said cavities, and

d. electrical conducting means disposed between the connecting said overload protector means and one of said electrical connector means and extending outwardly from one of said openings to said peripheral edge and also extending at least partially around said block outwardly of said peripheral edge of said block between the overload protector means and said one of said electrical connector means.

2. A cluster assembly for making a gang connection to a plural post terminal having:

a. a series of cavities formed in the face of a mounting block,

b. said cavities opening outwardly to the edge of said mounting block,

c. electrical terminals disposed in some of said cavities and connected to electrical leads disposed in and extending from some of said cavities,

d. an overload protection means disposed in another of said cavities, and

. one of said electrical leads extending from one of said cavities and in electrical connection with said overload protection means disposed in said another of said cavities, and,

electrical conducting means extending from said overload protection means outwardly of its cavity and joined to one of said extending leads to thereby from an assemblage.

The combination set out in claim 2 wherein:

said overload protection means cavity includes groove means and,

b. said overload protection means includes means fittin g in said groove means for maintaining its position in said overload protection means cavity.

4. The combination set out in claim 3, wherein;

a. said groove means is partially annular and,

b. said means fitting in said groove means comprises a circular flange.

5. The combination set out in claim 3 wherein;

a. said overload protection means includes oppositely extending terminals, and

b. said overload protection means cavity includes channel means for receiving said oppositely disposed terminals in a holding relationship.

6. The combination set out in claim 3 wherein;

a. a cover means is provided for said mounting block,

b. said mounting block includes a plurality of upstanding tabs, and

c. said cover means abuts said upstanding tabs in assembled positions on said mounting block.

7. The combination set out in claim 6 wherein;

a. said mounting block takes the form of a truncated,

peaked member. 

1. A CLUSTER ASSEMBLY FOR MAKING A GANG CONNECTION TO A PLURAL POST TERMINAL INCLUDING; A. A MOUNTING BLOCK HAVING A PERIPHERAL EDGE AND A PAIR OF OPPOSITELY DISPOSED FACES, SAID MOUNTING BLOCK HAVING A PLURALITY OF CAVITIES DISPOSED IN ONE OF SAID FACES, SAID CAVITIES OPENING TO SAID PERIPHERAL EDGE, B. ELECTRICAL CONNECTOR MEANS DISPOSED IN AT LEAST SOME OF SAID CAVITIES, C. AN OVERLOAD PROTECTOR MEANS DISPOSED IN ONE OF SAID CAVITIES, AND D. ELECTRICAL CONDUCTING MEANS DISPOSED BETWEEN AND CONNECTING SAID OVERLOAD PROTECTOR MEANS AND ONE OF SAID ELECTRICAL CONNECTOR MEANS AND EXTENDING OUTWARDLY FROM ONE OF SAID OPENINGS TO SAID PERIPHERAL EDGE AND ALSO EXTENDING AT LEAST PARTIALLY AROUND SAID BLOCK OUTWARDLY OF SAID PERIPHERAL EDGE OF SAID BLOCK BETWEEN SAID OVERLOAD PROTECTOR MEANS AND SAID ONE OF SAID ELECTRICAL CONNECTOR MEANS.
 2. A cluster assembly for making a gang connection to a plural post terminal having: a. a series of cavities formed in the face of a mounting block, b. said cavities opening outwardly to the edge of said mounting block, c. electrical terminals disposed in some of said cavities and connected to electrical leads disposed in and extending from some of said cavities, d. an overload protection means disposed in another of said cavities, and e. one of said electrical leads extending from one of said cavities and in electrical connection with said overload protection means disposed in said another of said cavities, and, f. electrical conducting means extending from said overload protection means outwardly of its cavity and joined to one of said extending leads to thereby form an assemblage.
 3. The combination set out in claim 2 wherein: a. said overload protection means cavity includes groove means and, b. said overload protection means includes means fitting in said groove means for maintaining its position in said overload protection means cavity.
 4. The combination set out iN claim 3, wherein; a. said groove means is partially annular and, b. said means fitting in said groove means comprises a circular flange.
 5. The combination set out in claim 3 wherein; a. said overload protection means includes oppositely extending terminals, and b. said overload protection means cavity includes channel means for receiving said oppositely disposed terminals in a holding relationship.
 6. The combination set out in claim 3 wherein; a. a cover means is provided for said mounting block, b. said mounting block includes a plurality of upstanding tabs, and c. said cover means abuts said upstanding tabs in assembled position on said mounting block.
 7. The combination set out in claim 6 wherein; a. said mounting block takes the form of a truncated, peaked member. 